Aerodynamic toolbox assembly

ABSTRACT

Embodiments provide an aerodynamic toolbox assembly comprising a toolbox coupled to a tractor trailer and an aerodynamic fairing assembly coupled to the toolbox. At least one fairing component extends beyond a selected surface of the toolbox to facilitate aerodynamic air flow past the toolbox during normal operation of the trailer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims a benefit of priorityunder 35 U.S.C. 120 of, U.S. patent application Ser. No. 16/630,318filed Jan. 10, 2020, issued as U.S. Pat. No. 11,352,073, entitled“AERODYNAMIC TOOLBOX ASSEMBLY,” which is a 35 U.S.C. 371 national stageapplication to International Application No. PCT/US2018/041907 filedJul. 12, 2018, entitled “AERODYNAMIC TOOLBOX ASSEMBLY,” which claims abenefit of priority to U.S. Provisional Patent Application No.62/531,782 filed Jul. 12, 2017, entitled “AERODYNAMIC TRUCK BOXES”,which are hereby incorporated herein for all purposes.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to aerodynamic toolbox assemblies for vehicles.

2. Description of the Related Art

In general, in the descriptions that follow, we will italicize the firstoccurrence of each special term of art that should be familiar to thoseskilled in the art of vehicular fairing systems. In addition, when wefirst introduce a term that we believe to be new or that we will use ina context that we believe to be new, we will bold the term and providethe definition that we intend to apply to that term.

Hereinafter, when we refer to a facility we mean a mechanical,hydraulic, electrical or electronic device or an associated set of suchdevices adapted to perform a particular function regardless of thephysical or circuit layout of an embodiment thereof. However, unless weexpressly state to the contrary, we consider the form of instantiationof any facility that practices our invention as being purely a matter ofdesign choice.

Large vehicles such as semis may easily travel several thousand mileseach month, including on highways and other routes which allow forhigher speeds. Poor aerodynamics cause a decrease in fuel economy and anincrease in operating cost. Therefore, there is a need to improve theaerodynamics of such vehicles, and, thus, the fuel efficiency thereof.

BRIEF SUMMARY OF THE INVENTION

Embodiments described herein provide systems and methods for improvingthe aerodynamics of toolboxes mounted on vehicles, and, in particular,tractor and trailer vehicles. Embodiments may also be beneficial onother vehicles as well.

In one embodiment, an aerodynamic fairing facility is provided for usewith a vehicle-mounted toolbox comprising: a top panel; a bottom panel;a rear panel; a first side panel; and a second side panel. In thisembodiment, the aerodynamic fairing facility comprises: a first fairingpanel coupled to a selected one of the top panel, the bottom panel, thefirst side panel and the second side panel of the toolbox, the firstfairing panel being configured so as to extend beyond a selected one ofthe top panel, the bottom panel, the first panel and the second panel ofthe toolbox.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a more complete understanding of the present disclosure and theadvantages thereof, reference is now made to the following descriptiontaken in conjunction with the accompanying drawings in which likereference numerals indicate like features and wherein:

FIG. 1 depicts a perspective view of one embodiment of an aerodynamictoolbox assembly mounted under a tractor trailer;

FIG. 2 depicts a perspective view of the embodiment of FIG. 1 ,illustrated with the second door thereof open;

FIG. 3 depicts a partial perspective view of the embodiment of FIG. 1illustrated with the first top fairing extension folded down;

FIG. 4 depicts a side view of the embodiment of FIG. 1 ;

FIG. 5 depicts, in isolation, the embodiment of FIG. 1 , illustratedwith both doors open;

FIG. 6 depicts, in partial exploded form, the embodiment of FIG. 1 ;

FIG. 7 depicts the rear view of the doors of the embodiment of FIG. 1 ;

FIG. 8 depicts the front view of the doors of the embodiment of FIG. 1 ;

FIG. 9 depicts a perspective view of a second embodiment of anaerodynamic toolbox assembly mounted under a tractor trailer;

FIG. 10 depicts a perspective view of the embodiment of FIG. 9 ,illustrated with the door thereof open;

FIG. 11 depicts a side view of the embodiment of FIG. 10 ;

FIG. 12 , comprising FIG. 12A and FIG. 12B, depicts one embodiment ofthe socket attachments of the fairing components of FIG. 10 ;

FIG. 13 depicts another perspective view of the embodiment of FIG. 10 ;

FIG. 14 depicts the embodiment of FIG. 13 with the door open;

FIG. 15 depicts a rear view of the embodiment of FIG. 10 ;

FIG. 16 depicts, in front perspective exploded form, the embodiment ofFIG. 10 ;

FIG. 17 depicts, in rear perspective exploded form, the embodiment ofFIG. 10 ;

FIG. 18 depicts a top plan view of the embodiment of FIG. 10 ;

FIG. 19 depicts a side perspective of a self-latching plug configured tocouple to a socket of the embodiment of FIG. 12 ;

FIG. 20 depicts a cross-sectional view of the self-latching plug of FIG.19 coupled to a socket of the embodiment of FIG. 12 ;

FIG. 21 depicts a perspective view of an alternate embodiment of thetoolbox of FIG. 10 ;

FIG. 22 , comprising FIG. 22A, FIG. 22B, FIG. 22C, FIG. 22D, FIG. 22E,FIG. 22F, FIG. 22G, FIG. 22H, FIG. 22I, FIG. 22J, FIG. 22K and FIG. 22L,depicts, in top plan view form, alternative embodiments of theembodiment of FIG. 10 ;

FIG. 23 , comprising FIG. 23A, FIG. 23B, FIG. 23C, FIG. 23C, FIG. 23D,FIG. 23E, FIG. 23F, FIG. 23G, FIG. 23H, FIG. 23I, FIG. 23J, FIG. 23K andFIG. 23L, depicts a third embodiment of an aerodynamic toolbox;

FIG. 24 , comprising FIG. 24A, FIG. 24B and FIG. 24C, depicts a fourthembodiment of a toolbox having a mud flap coupled thereto;

FIG. 25 , comprising FIG. 25A, FIG. 25B, FIG. 25C and FIG. 25D, depictsa fifth embodiment of an aerodynamic toolbox;

FIG. 26 , comprising FIG. 26A, FIG. 26B, FIG. 26C and FIG. 26D, depictsa sixth embodiment of an aerodynamic toolbox;

FIG. 27 , comprising FIG. 27A and FIG. 27B, depicts a seventh embodimentof an aerodynamic toolbox;

FIG. 28 , comprising FIG. 28A and FIG. 28B, depicts an eighth embodimentof an aerodynamic toolbox;

FIG. 29 , comprising FIG. 29A, FIG. 29B, FIG. 29C and FIG. 29D,illustrates a method for pivotally coupling the front fairing to a doorof an aerodynamic toolbox so as to allow rotation of the door beyond90°;

FIG. 30 , comprising FIG. 30A, FIG. 30B, FIG. 30C and FIG. 30D, depictsa ninth embodiment of an aerodynamic toolbox; and

FIG. 31 depicts a tenth embodiment of an aerodynamic toolbox.

In the drawings, similar elements will be similarly numbered wheneverpossible. However, this practice is simply for convenience of referenceand to avoid unnecessary proliferation of numbers, and is not intendedto imply or suggest that our invention requires identity in eitherfunction or structure in the several embodiments.

DETAILED DESCRIPTION OF THE INVENTION

The disclosure and various features and advantageous details thereof areexplained more fully with reference to the exemplary, and thereforenon-limiting, embodiments illustrated in the accompanying drawings anddetailed in the following description. Descriptions of known startingmaterials and processes may be omitted so as not to unnecessarilyobscure the disclosure in detail. It should be understood, however, thatthe detailed description and the specific examples, while indicating thepreferred embodiments, are given by way of illustration only and not byway of limitation. Various substitutions, modifications, additionsand/or rearrangements within the spirit and/or scope of the underlyinginventive concept will become apparent to those skilled in the art fromthis disclosure.

As used herein, the terms “comprises”, “comprising”, “includes”,“including”, “has”, “having”, or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,product, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, product,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive or and not to an exclusive or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

Additionally, any examples or illustrations given herein are not to beregarded in any way as restrictions on, limits to, or expressdefinitions of, any term or terms with which they are utilized. Insteadthese examples or illustrations are to be regarded as being describedwith respect to one particular embodiment and as illustrative only.Those of ordinary skill in the art will appreciate that any term orterms with which these examples or illustrations are utilized encompassother embodiments as well as implementations and adaptations thereofwhich may or may not be given therewith or elsewhere in thespecification and all such embodiments are intended to be includedwithin the scope of that term or terms. Language designating suchnon-limiting examples and illustrations includes, but is not limited to:“for example”, “for instance”, “e.g.”, “in one embodiment”, and thelike. Furthermore, any dimensions, materials or other suchcharacteristics are provided by way of example and not limitation.

Embodiments described herein provide systems and methods for improvingthe aerodynamics of toolboxes mounted on vehicles, and, in particular,tractor and trailer vehicles. Embodiments may be particularly suited forreducing aerodynamic drag, reducing or otherwise controlling thegeneration or distribution of spray/splash or improving the stability oflarge vehicles in an airstream.

Shown in FIG. 1 is a partial cutaway view of a tractor trailer 10 havingmounted thereunder an aerodynamic toolbox assembly 12 constructed inaccordance with the present invention. In general, the aerodynamictoolbox assembly 12 comprises a conventional toolbox 14 and anaerodynamic fairing facility 16. As can be seen best in FIG. 5 and FIG.7 , the toolbox 14 comprises: a top panel 18; a bottom panel 20; a rearpanel 22; a first side panel 24; a second side panel 26; and a doorpanel 28 comprising a first door panel 28D1 and a second door panel28D2. As shown by way of example in FIG. 7 , the toolbox 14 may besuspended beneath the trailer 10 via a conventional mounting bracket 30.

In the embodiment illustrated in FIG. 1 through FIG. 8 , the aerodynamicfairing facility 16 comprises: a first fairing assembly 16F1 comprisinga first main fairing 16M1 coupled via bolts 32 to the first door 28D1 ofthe toolbox 14 (see, e.g., FIG. 5 ) and a first top fairing 16T1 coupledvia one or more spring hinges 34 to the top edge of the first mainfairing 16M1 (see, e.g., FIG. 7 ); and a second fairing assembly 16F2comprising a second main fairing 16M2 coupled via bolts 36 to the seconddoor 28D2 of the toolbox 14 (see, e.g., FIG. 5 ) and a second topfairing 16T2 coupled via one or more spring hinges 38 to the top edge ofthe second main fairing 16M2 (see, e.g., FIG. 7 ). In this embodiment,at least one of the fairing assemblies 16F1 and 16F2 is configured toextend beyond one of the edges of the front panels 28D1 and 28D2,respectively, of the toolbox 14, thereby to improve the aerodynamic flowof air past the toolbox 14 during normal operation of the trailer 10.For example, as shown in FIG. 5 , the second main fairing 16M2 of thesecond fairing assembly 16F2 is configured to extend verticallydownwardly below the bottom edge of the second front door panel 28D2 ofthe toolbox 14; further, the second main fairing 16M2 of the secondfairing assembly 16F2 is also configured to extend horizontallyrearwardly (i.e., with respect to the normal direction of travel of thetrailer 10) beyond the second edge of the second front door panel 28D2of the toolbox 14. In addition, the second top fairing 16T2 of thesecond fairing assembly 16F2 is spring biased so as generally to extendvertically upwardly above the top edge of the second front door panel28D2 of the toolbox 14. The first fairing assembly 16F1 is similarlyconfigured. In this embodiment, either the first top fairing 16T1 or thesecond top fairing 16T2 may easily be rotated backwardly about thehorizontal rotational axes of hinges 36 or 38, respectively, i.e.,toward the top panel 18 of the toolbox 14, so as to accommodate, interalia, a conventional sliding ratchet wrench 40 (see, e.g., FIG. 3 ).

Although, in the embodiment illustrated in FIG. 1 through FIG. 8 , wehave shown the fairing assemblies 16 as being removably coupled torespective door panels 28 of the toolbox 14, the fairing assemblies 16and the door panels 28 can easily be combined so as to form integralaerodynamic fairing door panels (see, e.g., FIG. 25 ), each pivotallyconnected to a selected one of the top panel 18, the bottom panel 20,the first panel 24 or the second panel 26.

In the embodiment illustrated in FIG. 9 through FIG. 18 , theaerodynamic toolbox assembly 42 comprises a toolbox 44 and anaerodynamic fairing facility 46. As can be seen in FIG. 16 , the toolbox44 is configured with a plurality of receiver sockets 48 coupled to thefront edges of each of the top panel 50, bottom panel 52, the firstpanel 54 and the second panel 56. As can be seen in FIG. 17 , theaerodynamic fairing facility 46 comprises a top fairing panel 58, bottomfairing panel 60, a first side fairing panel 62 and a second sidefairing panel 64, each configured with a plurality of plugs 66 adaptedto couple with respective sockets 48 on the toolbox 44. In oneembodiment, shown in FIG. 12 , each plug 66 can be removably coupled toa respective socket 48 via a captive pin 68 or the like. In one otherembodiment, shown in FIG. 19 and FIG. 20 , one or more of the plugs 66can be configured to be self-latching. In yet another embodiment, thereceiver sockets 48 for at least some of the fairing panels, e.g., theside fairing panels 62-64, are coupled to the edges of door panel 70 ofthe toolbox 44 as shown in FIG. 21 .

Shown in FIG. 22 are several alternative cross-sectional configurationsof the leading (depicted at the top of the respective figures) andtrailing (depicted at the bottom of the respective figures) side fairingpanels 62-64. As shown in FIG. 22A through FIG. 22D, the aerodynamicpanels at the leading edge and at the trailing edge may be straight,angled, S-curved, rounded with a radius, or of a varying number ofshapes that may be preferable for aerodynamics. FIG. 22E, FIG. 22G andFIG. 22H show how the shape of the front and rear of the toolbox mayprovide an outward-facing fairing surface as well as an inward-facingfairing surface. These embodiments also demonstrate how the structure ofthe toolbox can be modified whereby the fairings can increase therigidity and/or the storage space of the toolbox. FIG. 22F illustrateshow the fairings may provide venting or ducts in order to controlairflow in a preferable method. FIG. 22I illustrates how theleading/trailing fairings may have supports that mount to the front andrear panels of the toolbox and extend inward by a portion of the depthof the toolbox. FIG. 22J shows a leading fairing configured to besupported by a suitable mechanism such as a hinging mechanism, a springmechanism, a shock-absorbing mechanism, or otherwise. FIG. 22K and FIG.22L show how the aerodynamic panels may be telescopic and thus can bestowed inside the doors of the toolbox or adjacent to the doors of thetoolbox, respectively.

In the embodiment shown in FIG. 23 , the aerodynamic toolbox assembly 70comprises a shaped toolbox 72 configured such that the shaped door panel74 provides an aerodynamic surface that has a leading edge furtherinboard than the trailing edge. While the use of a toolbox having afixed shape may not be preferable due to the requirement for a differenttoolbox for mounting on the left side or right side of the vehicle, thisembodiment shows how toolbox 70 can be configured with a reversible doorpanel and a relocatable door hinge that can allow the same toolboxassembly to be used on both sides of the vehicle. Also in thisembodiment, it can be seen that the dimensions of the first and secondside panels may be selected so as to improve the aerodynamiccharacteristics of the shaped toolbox 72.

In the embodiment shown in FIG. 24 , the toolbox 44 of, e.g., FIG. 16 isconfigured to support a mud flap 76 coupled to a flange 78 coupled to,and extending below, the lower edge of the trailing side panel oftoolbox 44. In some applications, it may be desirable for otheraccessories, such as tire chain hangers, to mount to the toolbox in asimilar manner.

In the embodiment shown in FIG. 25 , the aerodynamic toolbox assembly 80comprises a toolbox 82 and an aerodynamic fairing facility 84. As canbest be seen in FIG. 25C, the aerodynamic fairing facility 84 comprisesan integrated front door panel 86, a top fairing panel 88, a bottomfairing panel 90, a first side fairing panel 92 and a second sidefairing panel 94.

In the embodiment shown in FIG. 26 , the aerodynamic toolbox assembly 96comprises a toolbox 98 and an aerodynamic fairing facility 100. As canbest be seen in FIG. 26C and FIG. 26D, the aerodynamic fairing facility100 comprises a front door panel 102, a top fairing panel 104, a bottomfairing panel 106, a center fairing panel 108, a first side fairingpanel 110 and a second side fairing panel 112.

In the embodiment shown in FIG. 27 , the toolbox 114 is configured withan aerodynamic fairing 116 comprising a passageway or duct behind theback panel of the toolbox 114. In this embodiment, this additionalfairing 116 can be mounted to the frame of the vehicle and/or to thetoolbox 114. As desired, the fairing 116 may be enclosed partially orcompletely. Further, the fairing 116 can be configured so that the airmay be directed rearward and inward/outward/upward/downward. The fairing116 may also be configured to direct cooling airflow to the vehiclesbrakes (not shown). Further, the fairing 116 may be configured to directairflow outward, thereby to augment the airflow being deflected by theoutside surface of the toolbox/rear fairing. The fairing 116 may also belocated above or below the toolbox 114.

In the embodiment shown in FIG. 28 , the toolbox 118 is configured withmeans for adjusting the length thereof, thereby providing a variablelength aerodynamic toolbox assembly when combined with any of theseveral aerodynamic fairing configurations disclosed herein. In thisembodiment, the toolbox 118 comprises first and second end portions, 120and 122, respectively, and one center portion 124. Each of the endportions 120-122 overlaps the center portion 124 by a length which canbe configured by the user when installing the toolbox 118.Alternatively, the center portion 124 could be eliminated, and the twoend portions 120-122 may be configured to overlap each other therebyaccomplishing the same purpose. The toolbox 118 could also be configuredwith a center portion 124 which couples directly to the end portions120-122, wherein the center portion 124 comprises any of a plurality ofdifferent lengths. Other methods of providing adjustable or selectablelength mechanical assemblies could be adapted to accomplish the same forthe toolbox 118. One benefit of having an adjustable length toolbox 118may include, for example, being able to maximize the surface area of theaerodynamic outer surface between the axles of a trailer, whereby thedistance between the axles may vary widely. Another benefit of having anadjustable length toolbox 118 may be that fewer total parts are requiredto provide a plurality of desired lengths. A further benefit may be thatthe toolbox 118 requires less volume when being stored in a warehouse orwhen being shipped.

Shown in FIG. 29 is a front fairing panel 126 is pivotally coupled to adoor 128 of an aerodynamic toolbox 130 via a hinge 132 (for clarity,shown only in FIG. 29A), thereby allowing rotation of the door 128beyond 90° relative to front of the toolbox 130. In this embodiment, alatch hook 134 is configured to lock the fairing panel 126 in place whenthe door 128 is closed, thereby preventing wind force from making thefairing panel 126 rotate while the vehicle is in motion, while stillallowing the fairing panel 126 to automatically move out of the way whenthe door 128 is fully opened. The hinge 132 may be, e.g., a spring hingeconfigured so that the fairing may return to its locked position whenthe door 128 is closed.

In the embodiment shown in FIG. 30 , the toolbox 136 per se isconfigured to have an overall aerodynamic shape. In each of the severalillustrated variants, additional storage space is obtained within theaerodynamically-shaped extensions of the toolbox 136.

In the embodiment shown in FIG. 31 , a plurality of aerodynamic toolboxassemblies 138, each similar in construction and arrangement to theembodiment of FIG. 24 , are mounted adjacent to each other on thevehicle frame, and an inter-box fairing 140 is configured so as to coverthe gap between each pair of toolboxes 138. In this embodiment, a topfairing panel 142 is coupled via a hinge (not shown) to the top edge ofthe inter-box fairing 140 (see, e.g., FIG. 3 ).

In the description herein, numerous specific details are provided, suchas examples of components and/or methods, to provide a thoroughunderstanding of embodiments of the invention. One skilled in therelevant art will recognize, however, that an embodiment may be able tobe practiced without one or more of the specific details, or with otherapparatus, systems, assemblies, methods, components, materials, parts,and/or the like. In other instances, well-known structures, components,systems, materials, or operations are not specifically shown ordescribed in detail to avoid obscuring aspects of embodiments of theinvention. While the invention may be illustrated by using a particularembodiment, this is not and does not limit the invention to anyparticular embodiment and a person of ordinary skill in the art willrecognize that additional embodiments are readily understandable and area part of this invention.

The invention claimed is:
 1. An aerodynamic fairing system for use witha vehicle-mounted toolbox comprising: an aerodynamic fairing assemblyadapted to be integrated with a toolbox mounted to a vehicle, thetoolbox comprising a front panel, a top panel, a bottom panel, a rearpanel, a first side panel and a second side panel, the aerodynamicfairing assembly comprising: at least one fairing integrated with one ormore of the top panel of the toolbox, the bottom panel of the toolbox,the first side panel of the toolbox and the second side panel of thetoolbox.
 2. The aerodynamic fairing system of claim 1, wherein the atleast one fairing is further adapted to extend beyond a selected one ormore of the top panel, the bottom panel, the front panel, or the rearpanel.
 3. The aerodynamic fairing system of claim 1, wherein the one ormore of the front panel, the top panel, the rear panel, or the bottompanel is configured to pivot.
 4. The aerodynamic fairing system of claim1, wherein a length of the toolbox is adjustable.
 5. The aerodynamicfairing system of claim 1, wherein the toolbox is adapted to removablyreceive one or more additional aerodynamic fairings.
 6. The aerodynamicfairing system of claim 1, wherein the toolbox is adapted to removablyreceive one or more mud flaps.
 7. The aerodynamic fairing system ofclaim 1, wherein the toolbox comprises a door shaped to direct air flowrearward and outward.
 8. The aerodynamic fairing system of claim 7,wherein the toolbox comprises a door angled outward.
 9. The aerodynamicfairing system of claim 7, wherein the toolbox comprises a curved door.10. The aerodynamic fairing system of claim 7, wherein the toolboxcomprises one or more reversible doors adapted to allow the toolbox tobe configured as a mirror image on each side of the vehicle.
 11. Theaerodynamic fairing system of claim 1, wherein the toolbox comprises adoor providing an aerodynamic surface with a leading edge furtherinboard than a trailing edge.
 12. The aerodynamic fairing system ofclaim 1, wherein one or more of a fairing leading edge of the at leastone fairing or a fairing trailing edge of the at least one fairing isshaped to a curvature of one or more wheels located adjacent to thetoolbox.
 13. The aerodynamic fairing system of claim 1, wherein the atleast one fairing is adapted to increase a storage area of the toolbox.14. The aerodynamic fairing system of claim 1, wherein the one or morefairings are shaped to direct air flow rearward and outward.
 15. Anaerodynamic toolbox, comprising: a toolbox for use with a vehicle, thetoolbox comprising a top panel, a bottom panel, a rear panel, a firstside panel, a second side panel, and one or more doors adapted to reduceaerodynamic drag by directing airflow outward and rearward, wherein: thefirst side panel is located in front of the one or more doors andproximate to the front of the vehicle when installed on the vehicle, andthe second side panel is located behind the one or more doors andproximate to the rear of the vehicle when installed on the vehicle; andthe first side panel is smaller than the second side panel of thetoolbox, thereby positioning the leading edge of the one or more doorsinboard of the trailing edge of the one or more doors when installed onthe vehicle.
 16. The aerodynamic toolbox of claim 15, wherein one ormore fairings are integrated with one or more of the top panel of thetoolbox, the bottom panel of the toolbox, the first side panel or thesecond side panel.
 17. The aerodynamic toolbox of claim 15, wherein theone or more doors are angled in relation to the rear panel of thetoolbox.
 18. The aerodynamic toolbox of claim 15, wherein the one ormore doors are curved.
 19. The aerodynamic toolbox of claim 15, whereinthe one or more doors are reversible to allow the toolbox to beinstalled as a mirror image on each side of the vehicle.
 20. Theaerodynamic toolbox of claim 15, wherein one or more of the leading edgeand the trailing edge is shaped to the curvature of a wheel locatedadjacent to the toolbox when installed on the vehicle.